Laundry Washer Recirculation Control for Early Wetting and Suds Reduction
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Solution Overview
Problem
Front load washing machines face a contradiction between minimizing excess suds formation and maximizing the use of water recirculation, which affects wash performance and water consumption.
Innovation Solution
Coordinating short bursts of recirculation pump operation with tub rotation during initial fill periods and modifying intermediate spins to carry over water from one cycle to the next, while intermittently activating the recirculation pump to recharge detergent and reduce water usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the recirculation pump is used extensively to wet clothes early in wash cycles, then wash performance is improved, but excess suds formation occurs that cannot be effectively removed during rinse cycles
Solution Approach 1:
The recirculation pump operates in periodic bursts rather than continuously. During wash cycles, the pump runs for predetermined time intervals (e.g., 5-15 seconds) followed by pause periods, creating a rhythmic on-off pattern. This periodic operation allows water to be recirculated and clothes to be wetted effectively while preventing excessive suds accumulation that would occur with continuous operation.
Solution Approach 2:
The system dynamically adjusts recirculation pump operation based on cycle phase and conditions. During initial fill periods, the pump operates more frequently to maximize wetting. During rinse cycles, the pump operation is reduced or modified to prevent suds lock. The control system monitors and adjusts pump runtime, pause intervals, and operational intensity to match the specific needs of each cycle phase, transitioning from aggressive recirculation in wash to conservative recirculation in rinse.
2Object-generated harmful factors
If the recirculation pump is used on a limited basis to avoid excess suds, then suds control is improved, but wash performance is reduced due to insufficient wetting of clothes
Solution Approach 1:
The recirculation pump is activated during initial fill periods before the main wash cycle begins. This preliminary operation ensures clothes are thoroughly wetted with detergent solution early, maximizing detergent penetration and wash effectiveness. By performing the wetting action in advance, the system achieves good wash performance without requiring extensive recirculation during the entire wash cycle, thus avoiding excess suds formation later.
Solution Approach 2:
The system maintains continuous useful action through coordinated operation of the recirculation pump with drum rotation and fill operations. During initial fill, the pump operates continuously in brief bursts to maximize wetting. During wash, the pump alternates with drum agitation to maintain detergent distribution. This continuous coordinated operation ensures clothes remain adequately wetted throughout the cycle without requiring the pump to run at full intensity continuously, thereby balancing wash performance with suds control.
3Loss of substance
If intermediate spin extractions are performed to remove water from clothes, then water consumption is reduced in subsequent cycles, but less water is carried over to the next wash/rinse cycle reducing recirculation effectiveness
Solution Approach 1:
The system applies partial spin extraction rather than complete water removal during intermediate cycles. Instead of spinning at high speed to remove all excess water, the drum rotates at lower speeds for shorter durations, retaining a controlled amount of water in the clothes. This partial extraction reduces overall water consumption compared to aggressive spinning while maintaining sufficient moisture in clothes to enable effective recirculation in the next cycle, creating an optimal balance between water savings and recirculation utility.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances wash performance by thoroughly wetting clothes early in cycles, reduces suds formation, and conserves water by allowing earlier recirculation initiation and lower water levels, thereby improving rinse efficiency and overall cycle effectiveness.
Implementation Method 1
a recirculation pump and system that allows the water inside the wash tub to be recirculated from bottom to top
Implementation Method 2
high speed drum rotations plaster the clothes against the walls of the tub and water is extracted from the clothes by the centrifugal force
Implementation Method 3
The main function of the rinses is to remove detergent from the clothes after the wash portion of the cycle
Data Source
AI summary
In a laundry washer, relatively short bursts of operation of a recirculation pump are coordinated with corresponding brief intervals of tub rotation during the initial fill periods. The aim is to thoroughly wet the clothes early in each wash/rinse phase to thus improve the wash/rinse effectiveness, while also avoiding excessive suds formation. Following the initial fill periods and during regular wash/rinse agitations, the recirculation system may also be employed to “recharge” the laundry load with detergent that has settled in the bottom of the tub. In a further aspect of the invention, some or all of the conventional intermediate spin extractions are omitted. In this manner, more water is carried over in the clothes from one wash/rinse cycle to the next. An intermediate spin of reduced speed (RPM) and duration as compared to typical normal intermediate spins may be employed between the wash phase and first rinse.